DELTA ESI Design for Reliability Score Card Doc.

No - QF/DPS/232(1)
Rev.No - 00
Prototype EVT DVT PVT Dated - 01.12.2010

Model： Customer：

Revision： Review date：

Score Card SIGN

Total DFx Total DFx
Score QE Engineer Approved by
Possible Points Compliance Points

183 0 0%

Formula = Total Compliance Points / Total Possible Points ＊ Calculation Method

Priority 1 = 5 Points (High impact to warrenty cost and/or customer experience) 1) Prototype：Score ≧ 85 = Approval、< 85 = Reject
Priority 2 = 3 Points (Mid impact to warrenty cost and/or customer experience) 2) EVT、DVT、PVT：Score ≧ 90 = Approval、< 90 = Reject
Priority 3 = 1 Point (Low impact to warrenty cost and/or customer experience)

＊ Design for Reliability Check List

DFx Compliance Max Points Max Points
Item DFx Requirements Priority Level
Points (Y、N、- ) Available Available
1. System Checklist

Input and Output termainals should be convenient for power dustribution. (There must be no stress that
1-1 3 1 0
may cause short circuit and electrical shock).

1-2 If the insulating cover is needed, the considerations of preventing contact short should be designed. 3 1 0

Have screwdriver adjustments been placed so that there is sufficient clearance for the
1-3 1 5 0
screwdriver handle?

1-4 Has consideration been given to the current rating of wire? 1 5 0

1-5 The AC and DC wires should be separated and considered to avoid the interference of magnetic field. 3 1 0

The reserved wires for customer use (such as battery cable) need to be definded the wire configuration
1-6 3 1 0
by Mechanical Engineer and its length can be successfully installed.

Burrs、sharp edges and tips in system (including spare parts and optional components) that could cause
1-7 3 1 0
damage to user/assembler are not allowable.

1-8 Any switch on the system should be considered to prevent inadvertently switch on/off. 3 1 0

The system appearance dimensions, slide dimensions and plug/sockets terminal dimensions need
1-9 to meet the design specifications and to verify its functionality. 2 3 0

The contact performance of all mechanical components such as grounding screws and connectors
1-10 should be contact well. If the AC/DC connector is designed on board, the pin number should be more 2 3 0
than 3 even if only 2 pins are used.

The criteria for Acoustic Noise is

60dB for systems if power system<500A
1-15 1 5 0
65dB for systems if 500A <power system<1000A
70dB for systems if power system>1000A

The foolproof design for connector and wire should not only be limited by labeling, the color-
1-16 coding、length control and different pin number can be used together with labeling to enhence the 1 5 0
foolproof design.

1-18 According to the meeting minutes for TQM on Dec-18-2007, ENG have to use the on board design for EEPROM and 1 5 0
CSU instead of socket. Besides, it need the terminal for the software upgrade.

1-19 The dection wires of LVDS should connect to load side not battery side. 1 5 0

1-20 The tightness of male and female socke must be enough to prevent slack. 3 1 0

After cuting the pin of device due to space limition, the device should be soldered again to prevent
1-21 2 3 0
potential issue such as solder crack.

1-22 Check all the devices that need to be glued are porperly in the process of construction. 3 1 0

The strength of narrow and long PWB need to be considered to avoid SMD crack during production
1-29 process. 2 3 0
Please enhance the PWB to avoid the SMD capacitors crack during process.

1-31 The painting loss, deformation, blotch and color difference of exterior parts are not acceptable. 1 5 0

1-32 System design shall consider to guard against the bugs, need to use stainless steel if system has bug reticulum. 1 5 0

The output connector should have correcting pin and the grounding pin should be long pin to avoid poor
contact.
1-33 3 1 0
Connectors must have the function to guide.
To keep the connector's conduction is good,grounding pin is longer than others.

If any transistor need to be locked on the thermal pad, the method of tightening should follow the
requirements in the material specification of thermal pad.
1-36 1 5 0
Fixation of the components on heat sink with Thermal Pad must follow the specification of Thermal Pad.
Ex. choose the low pressure spring clip.

1-37 If the component are used to the product in the first time,we need to rivew the spec. 1 5 0

2. Labeling Checklist
2-1 Are electrical terminals clearly marked (e.g. + or -, signal or ground)? 3 1 0

All labels of system shall meet customer's request, engineering drawing shall avoid wrong wording and/or
2-2 1 5 0
interfere with door or related component.

2-3 QE should confirm that the system wiring scheme is the same as wiring in the real system. 1 5 0

2-4 Are warning signs in accordance with the design and color-coding requirements. 1 5 0

3. Installation、Assembly and Maintenance Checklist

a. The wire configuration should keep away from sharp edges and keep distance from the heat source at
least 6mm.
3-1 3 1 0
b. The grounding busbars cannot interfere the wire configuration and equipment installation on customer
site.

The rating of Fuse printed on the PWB must same as the value of the BOM. This is to prevent assembly
3-2 1 5 0
and maintenance error when the PWB is common use on different system.

Any part that need to be installed by customer shall have the installation guide and the contents of
3-3 1 5 0
installation guide should be correct and reasonable.

3-4 Revised: Any Interference should be avoided during system assembly 1 5 0

The disassembly convenience and safety should be considered during maintenance. For example: the
disassembly of surge protector、fuse and breaker. The wire clamp should meet the requirements of Delta
3-5 1 5 0
Mechanical Workmanship Standard. The terminals and connectors should consuider to have foolproof
design.

a.Connectors shall be designed to easily operate for customer.

b.The wires set up by customer should be marked both of two end of wire for customer recognizing.
3-6 3 1 0
c.To avoid wire labeling misunderstand, do not use as like character of 1/I or W/M in the same time.
d.Connectors shall be designed to prevent wrong operating for customer.

The assembly of electromagnetic components must be tightened well and no slack problem. The coil
components should be appressed to the substrate and located in place and the configuration for the inlet
3-7 2 3 0
and outlet of wire should be defined.
The devices design shall be consider for maintenance worker.

Engineering should make sure the grounding methodology and provide suggestion with customer. All
3-8 these information should be marked in IOM document. (copper bus position、wire length and wiring 1 5 0
method)

4. Material Checklist

4-3 The epoxy type MLCC is forbidden for use. 1 5 0

4-4 The TOP Switchs are prohibit in aux power. 3 1 0

4-5 The MLCC used in DC output and PFC should be two MLCC in series or Dip type cap. 1 5 0

4-6 The connector material of relay should be AgSnO2 and meet the requirements of surge current of system. 1 5 0

5.Mechanical Check List

a.Mechanical devices of product shall not be damaged when products are inserted into the system or
5-1 removed from the system. 2 3 0
b.Customer's device should be smoothly plugged in and removed out from delta's system.

All components of the system should be tied securely and prevent slack and deformation during
5-2 3 1 0
transportation.

Engineering should provide the design basis to explain the trade-off between dust protection level and
5-3 1 5 0
heat dissipation capability.

5-4 The replacement time and installtion method of filter should be marked in IOM. 1 5 0

5-5 The filter location and fixed method should be considered as the protection against water and insects. 1 5 0

If the system consists of 2 cabinets, we need to confirm the height for both cabinet, the base plate of
5-6 1 5 0
outdoor system shall be integrated type.

When customer's equipment is above to our system, we need to consider adding insulator to avoid short
5-7 1 5 0
circuit if some of mechanical parts such as screw fall into system

Enclosure/screw/rivet exposed to outside: aluminum alloy or stainless steel

5-8 1 5 0
The external specific accessories such as screw, washer, nut shall be antirust material.

5-9 The important devices design shall be consider for maintenance worker. 3 1 0

6. Battery Check List

7.Others

7-3 The contents of accessory shall be conformed with customer's requirement. 1 5 0

7-4 Need to confirm shall we provide the tooling such as screw driver to customer if we have special parts. 1 5 0

COUNT 6 72 183 0
 DELTA PSBG II TPBU ISSUE LOG Doc.No - QF/DPS/232(2)
BOM Electronic Mech. Layout DOC Spec. Other Rev.No - 00
Dated - 01.12.2010
MODEL： Customer：
Revision： Review date：

Stage Category Issue NG Description SOLUTION OWNER DUE DATE CHECKER

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DELTA PSBG II TPBU PE Dept. Doc.No - QF/DPS/232(3)
Rev.No - 00
常 態 性 修 正 BOM 表 清 單 ✘ EVT DVT PVT Dated - 01.12.2010

Model： BOM rev.：

Item Module PART NO Q'ty Position Problem Owner Check

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